Method of sculpturing



June 16, 1953 c. ALBERT & .8

METHOD OF SCULPTURING Filed Dec. 28, 1949 2 Sheets-Sheet 1 /IV Vf/V T OR CAL V//V ,41.55 RT u WWW/WWW m ATTOAWEY c. ALBERT METHOD OF SCULPTURING June 16, 1953 Filed Dec. 28, 1949 Patented June 16, 1953 UNITED STATES PATENT OFFICE 10 Claims.

My present invention relates to new and unique sculptured statuary, models and other objects and articles composed of low-melting metals and alloys and to methods for producing the same.

Modeling, sculpturing and th like constitute extremely ancient arts which have been carried out in substantially their original form without major change or development. The modeling of statuary, figures and various articles from clay, plaster and similar materials as well as the soulpturing of various objects from stone, marble and other media are, therefore, well known and extensively practiced. These arts have for a long time sought some means or method whereby statuary, figures, objects, models and other articles could be fashioned from metal but this has not yet been realized so far as I am aware, except only insofar as bronze castings and the like have been produced. These, however, are both heavy and expensive and do not respond to this vention.

It is, accordingly, an object of the invention to provide, for the first time, means and methods whereby the sculpturing and modeling arts may be applied to and carried out in metale and metal alloys.

Another object of the invention resides in sculpturing and modeling procedure for the production from metal of various types of statuary, models and other objects in a simple, rapid manner but without the necessity for and expense of casting and characterized by the production of light, inexpensive and attractive articles.

A further object of the invention resides in a sculpturing or modeling procedure in which for the first time a medium is employecl which makes it possible to make major changes in configure.- tion and/ or to correct ortuitous errors or accidents as th medium is being shapecl to final form.

A still further object of the invention resides in the production of sculptured or modeled articles and objects from a low melting metal or metal alloy, generally without internal supports, and which article are susceptible of a variety of surface finishes, as hereinaiter set forth.

More specifically, an object of this invention involves the manual fashioning of low-melting point metal or metal alloy sheets or foil into a basic figure or object having the general Outline and distribution of material required for the final article but slightly larger than the same, followed by surface fusing and hardening of such .metal or metal alloy while imparting to the mass substantially its final contours, and then subjecting the same to any of a variety of optional nishing Operations.

Other and further objects and advantages will be understood and appreciated from the following description.

In the accompanying drawings wherein I have illustrated typical sculptured or modeled figures and a preferred procedure for producing the same;

Fig. l is a perspective View of a sheet of starting material of low melting metal alloy such as a tin-lead alloy;

Fig, 2 shows the initial crumpling odeformation of sheets of starting material into the beginnings of a desired object or article and indicating that the sheet-like material is relatively soft and pliant and capable of being bent, folded and shaped by manual pressure and manipulation into desired form.

Fig. 3 illustrates a typical basic figure or mass which is thereby orzned and which has been built up by crumpling and folding and otherwise suitably applying manual pressure to a number of starting sheets to produce the article or object in an intermediate stage in which it bears a general resemblance to the final article to be produced and has sufficient body and strength to maintain itself;

Figure 4 illustrates a succeeding step in the procedure in which surfac fusion and Smoothing of the basic figure of Fig. 3 has been carried out as by means of an electrically heated tool analogous to a soldering iron and showing a semi-finished surface;

Fig. 5 illustrates a further stage in the procedure which results from treatment with a finishing tool of the surface produced in Fig. 4 and showing a typical fine-grained surface which may, if desired, constitute the final finish;

Fig. 6 illustrates the application of the invention to the production of face masks and the like over 'a suitable support or form;

Fig. (sa is a top plan View of Fig. 6;

Fig. 7 is a vertical, medial section taken through Fig. 4 or 5 and particularly illustrates the dierences in the external and internal structure of the articles;

3 illustrates the application of the invention to a relatively slender or delicate form of model or figure which is provided with internal supports of wire or th like and Fig. 9 shows the application of the invention to the production of a relatively thin and hollow figure or model analogous to a thin casting.

In accordance with this invention, I have provided for the first time a procedure for modeling statuary and other objects and articles directly in metal without the necessity of following any of the usual costly procedures involved by casting which, to the best of my knowledge and belief, has until now been the only method for transforming artistic and industrial models into permanent metal articles. The invention is a relatively simple one which can be carried out without a great deal of skill and which, furthermore, overcomes the inability to change the model or article in material respects or to re-work it, as is the case With woocl, stone, plaster and other materials. While the procedure may, in its optional forms, involve the use of internal supports to give rigiclity or avoid destruction due to stresses and strains arising within the material due to the configurations imparted theretc, I have, for the first time, made it possible to produce lightweight articles of metal or metal alloys in final permanent form with a variety of surface finishes Without the necessity for using any rigid interior support of any sort and without producing articles which are dense and expensive. My invention also makes it possible. for the first time, to produce simple, inexpensive and light-weight fac'ial or other sculptured metallic masks. The procedure is characterized by both Simplicity and versatility and by the ability to produce metal articles in an extremely short period of time as compared with hitherto practiced procedures, especially casting procedures.

In general, my new and unique procedure comprises the following sequence of steps:

(1) Low melting metal or metal alloy foil or sheets are crumpled and deformed by manual compression and manipulation to produce the basic form of the article to be produced With sufficient strength and rigidity to maintain itself.

(2) The basic' form produced in step (1) is further manually molded, shaped and fashioned with the fingers until it approximates the model or article to be produced and this may involve the addition or removal of material and/or the further localized compression of such material until it is just slightly larger than the ultimate dimensions desired.

(3) A sculpturing or modeling tool which is preferably in the form of an electrically heated Stylus is applied progressively to various surfaces of the basic form to impart thereto the specific contours and configurations desired for the particular article or object and, as this heated stylus is passed over the compacted material, the surface is somewhat melted and fused to form a substantially solid and continuous crust of somewhat hardened metal and the over-all size of the article or object becomes somewhat reduced.

(4) The article is then subjected to any of various finishing operations which may be a final smoothing by means of a suitable tool or the provision of a special surface as by means of lacquering, electroplatng, Chemical oxidation or reduction and the formation of a desired patina.

I have discovered that thin sheets of a leadtin alloy are especially suitable for use in producing models and other articles in accordance with this invention and excellent results have been obtained through the use of a low-melting foil consisting of about 70% lead and about 30% tin, but it is to be understood that the invention is not in any way limited to the use of such an alloy since I have not only found that the proportions of lead and tin in the alloy may be varied but that relatively pure single metals may also be employed with entire success. For example, results were achieved with foil or sheets composed of about 60% lead and about 40% tin which were virtually as good as the 7 0-30% alloy and, depending upon the article involved and the desired appearance, weight and other features required, the lead-tin alloy may further vary and I have, in this connection, particularly found that a eutectic alloy composed of approximately 50% lead and 50% tin is entirely satisiactory. These alloys--particularly those containing about 60-70% lead and about 30-40% tin-are characterized by having not only a low-melting point but by existing in the liquid or molten phase over a considerable temperature range which may eX- tend to as much as about F. or more and, consequently, these alloys are particularly well adapted for the present purposes since they are readily softened and melted by the heated Stylus and do not re-solidify too quickly, thus enabling the desired contours to be imparted Without requiring unduly rapid action on the part of the sculptor or modeler, I have also employed pure tinfoil in the successful production of various models and, in general, I may use any low-melting point alloy such as Wood's metal or any pure or substantially pure metal just so long as it has a suitable or useful melting point preferably within the range of about 300-500 F. (about -300 C.). Alloys melting as low as about 117 F. (about 48 C.) may also be used and are particularly desirable in connection with children's modeling or hobby kits and sculpturing sets. It is, accordingly, to be understood that the choice of metal or metal alloy is a relatively wide one and depends upon factors which will be readily understood and appreciated. Corrosion resistance, is however, unnecessary and is, in most instances, undesirable since an attractive patina results from such surface changes.

In efiecting the change of physical form ci the sheet or foil starting material !B of Fig. 1 to that of Fig. 2, it will be observed that the crumpling and. compacting thereof produces a honeycomblike structure H made up of a plurality of folcls and bends of the sheet material and the formation 'of numerous fiattened air spaces The crumpling is carried out by applying moderate random pressure to the sheet material and is continued until, depending upon the shape to be produced, the materia is capable of standing alone and of maintaining itself without sagging or deformation. As many sheets of the starting material are used as are necessary to form a somewhat compacted mass which may be built-up by the addition of more sheets to special portions or reduced in certain portions by additional compacting or by tearing away the material until a basic form is produced such as that at !2 illustrated in Fig. 3 which, however, during-or subsequent to-its formation is molded and shaped by the pressure of the ng-ers until it bears an approximate likeness to the ultimate article to be produced but of a slightly larger size. These hand shaping and compacting Operations bring into play, and develop, the skill of the sculptor or modeler and provide all the needed activity to give expression to the creative instincts.

I especially wish to point out in this connection that the basic form or mass, such as that typifed by Fig. 3, is unique from a sculptofs or modeler's point of View in that for the first time it enables sculpturing and modelling to be carried out with metals and alloys and, moreove', afords opportunity -to make evenmajor changes in the model as it 'is being produced; that is to say, if the sculptor or modeler due to inexperience or inadvertence imparts the wrong or undesired configuration to the material, such can be readily corrected. Similarly, changes can be effected which result from a changed purpose or objective. If the amount of material involved is not large relative to the mass of the article, re-shaping can be carried out: by further compacting of the material through the exertion of additional manipw lated nger pressure thereon; by somewhat loosening or uncompaoting the material through appropriate pulling out of the same; by applying additional sheets of material at any points) and or by removing material at any pointis) and not only can these operations be carried out in this way by manual manipulations but such results canbe further adjusted, corrected and otherwise modified during the subsequent step of passing a heated Stylus over the thus-ashioned mass of material.

A heated stylus 13, such as that shown in Fig. 4, is prefe'ably a modified or special form of soldering iron which is mounted in a handle M connected through a conductor !5 to a source of electricity, but such Stylus need not necessariiy be heated by means oi an electrical resistance since it could, if desired, be a tip of reiatively high melting point metal or alloy, e. g., such as Copper.

which is heated through direct contact with a fiame or fire and then applied to the material or it may, optonally, be a self-heated tool. The temperature of the active end !6 of the styhs should be sufiiciently high to cause relatively rapid melting and fusing of the material when the Stylus is passed over` such material with a relatively light pressure and at a fairly rapid speed in a manner analogous to ironing The heated Stylus is used not only to impart the final contours and configurations to the model or article but to fuse and melt the material of the article throughout its external surfaces so as to. in effect, form a thin shell such as that indicateci at ll in Fig. '7, this shell being substantially solid and continuous and having little or no voids or air spaces. The heated Stylus is passed over the various portions of the material one or more times until precisely the desired contours are achieved and, in so doing, the amount of pressure exerted by the sculptor or modeler against 'the material by means of the Stylus may also be vared in the event that it is desired or required correspondingly to change the line of contour thereof.

An object or article [8, thus produced, and illustrated in Fig. 4, may be the final article, although such an article has a comparatively rough and unfinished surface and appearance which, however, is desirable in many cases especially where the nature of the model or article is such that the rough finish will enhance the effect which it is intended to produce. I have found, however, that it is generally preferable to p'oduce a smoother surface, such as that shown at !9 in Fig. 5, and this can readily be eifected by passing a suitable tool 20 such as a serrated or knurled file or rasp or a chisel or the like over some or all of the surfaces of the article or the smoothing may be effected by means of sandpaper, emery paper, emery cloth, steel wool and other media (not shown) to produce any desired type of finish from a relatively dull and rough one (matte) to a rela tively smooth and glossy one.

The resulting surface of whatever specific character it may be is then preserved, if desired, by

the application thereto of *a 'clearlacqu'er or the like which prevents oxidation and serves to main; tain the imparted surface characteristics. However, in some cases I have found that oxidation is desirable since it presents a very attractive type of surface finish for some articles or objects to give an appearance of antiquity, etc., or a special patina and thus oxidation may be deli berately produced by subjecting the article to changing weather conditions or, artificially, through the application 'of acids 'such as oxalic acid, vinegar and the like, in which latter case the oxidation stopped at the desired point by 'removing or neutralizing the residual acid, e. g., y rinsing and drying the same.

In addition, my invention contemplates the further finishing of the model or article by electroplating the same with copper, brass, cadmium, chromium or any other metal or alloy which can be applied by means of electro-deposition. Electroplating is advantageous in that it applies a very thin, continuous coat-ing of a desired metal or metallic material to the article which may be provided with the desired patina in the manner of castings or in one of the manners referred to above. Electrodeposition also gives, where desired, an additional hardening of the external surfaces and a. general protective coating to a model which is to be kept for a protracted period of time. After the production of such a model with an electrodeposited coating or skin, I may, optionally, subject the thus-produced model to a temperature just above the melting point of the lead-tin alloy or other metallic material from which the model was Originally formed but below the melting point of the electrodeposited metal or alloy so that the lower melting point material will melt and flow away, leaving a thinwalled hollow model or article having a strength approaching that of a casting of similar dimensions.

In referring above to low melting point metals and m tal alloys in sheet or foil form, it is also to be understood that the starting material may have other specific initial shapes, such as ribbons, wires and thin bars; and, further, that such material may be in the form of a coarse powder mixed with a, pliable substance such as a wax or resin which may be subsequently removed or in the form of filaments or haha I have found that the use of thin sheet material or foil is the best for most purposes but it is to be understood that for some articles the starting material may be of one of the other forms designated.

In some instances, also, it is desired to produce a form of article or model which is circumferentially incomplete and such a, form of article is particularly illustrated at ZI in Figs. 6 and Sa, wherein I have illustrated the production, according to this invention, of a metallio facial mask" or "portrait. In this case the materia-1 and steps are employed as already described but upon a. suitable supporting member 22 upon which it is built up and finally shaped, said member preferably but not necessarily having a configuration roughly resembling that of the article or object to be produced thereon. After completion, the mask can be readily stripped from the supporting member or in some cases the supporting member may be broken' or melted away or softened for easy removal by warming the same to a temperature sufficiently below the melting point of the mask material so as to avoid any deformation thereof.

In some -instances, also, due to the delicacy of the shape or figure being produced, I may optionally employ an internal support such as the wire skeleton 23 of Fig. 8 or the clay, plaster or other mandrel or support 24 of Fig. 9. In Fig. 8 the method of the present invention is carried out by applying the sheet material, foil, etc., to the wire or other skeleton 23 and in the case of Fig. 9 the article is formed upon the supporting material 24, which is then removed in any suitable way, as ndicated above, to provide a hollow article similar in its nature to a thin-walled &casting but without involving the difficulty and expense inherent in the production of such a casting and avoiding the density and weight of such a casting.

The present invention is adapted to be applied to a wide variety of uses in art and industry wherever models and other objects and articles are to be made. For example, sheets or foil of a low melting metal or alloy and a heatable stylus constitute an art or hobby kit from which objects may be fashioned. Sculptors may produce models of statues, figures, etc., as a guide for a full size work of art as Well as full scale and heroi-c size works. Industrial designers, city, building or park planners may readily produce and study models of their projects. Theatrical masks, stage set Components and other appurtenances may be inexpensively produced. On the other hand, permanent models, exhibits, works of art and commerce may be made in accordance with the invention. Other applications will occur to those skilled in this art.

An especial advantage of the present invention is that there is no loss of material as rejected sculptures and cut-off pieces can be melted down and re-used. In additon, other heating means or devices may be employed in place of a heated stylus such as a blow-torch, an electric resistance heating instrument, electric light bulbs and other heating media.

The foregoing is intended as illustrative and not as limitative since other and further modifications may be made without departing from the invention. The production of the figure or model upon a base or platform 25 is convenient and desirable but does not form a limitation upon the invention. The use of dyes, pigments and other coloring materials may also be utilized to r similar to but slightly larger than the ultimate model to be made, fusing the surfaces of said basi-c form by applying manually a heated device to produce a hardened and somewhat smoothed outer shell while imparting the final contours thereto and then subjecting the model so produced to a surface finishing operation.

2. A method in accordance with claim 1 in which the metallic material is a low melting allow.

3. A method in accordance with claim 1 in which the metallic material is a low melting alloy composed essentially of lead and tin.

4. A method in accordance with claim 1 in which the metallic material is a low melting alloy composed essentially of lead and tin in the relative proportions, by weight, of about -70% lead and about 50-30% tin.

5. A method in accordance With claim 1 in which the metallic material is a low melting alloy composed essentially of lead and tin in the relative proportions of approximately 70% lead and 30% tin.

6. A method in accordance with claim 1 in which the metallic material is a low melting alloy composed essentially of lead and tin in the relative proportions of approximately lead and 40% tin.

7. A method in accordance with claim 1 in which the metallic material is a low melting alloy -composed essentially of lead and tin in the relative proportions of approximately 50% lead and 50% tin.

8. A method in accordance with' claim 1 in which the metallic material is substantially pure tinfoil.

9. A method in accordance with claim 1 in which the metallic material is Wood's metal.

10. A method in accordance with claim 1 in which the surface fusion is carried out by passing a stylus heated to about 117-500 F. progressively over the basic form.

CALVIN ALBERT.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 256286 Cossell Apr. 11, 1882 438397 Benfield Oct'. 14, 1890 615,026 I-Iulbert Nov. 29, 1898 663,615 Scott Dec. 11, 1900 OTHER REFERENCES Electroforming by Safranek et al., Batelle Memorial Institute, Columbus, Ohio, published in Plating January 1948, pages 39-49. 

